tow MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

FRONT AXLE -Hub and Knuckle Assembly26-7
REMOVAL SERVICE POINTS
AA"CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
Caution
If the vehicle is equipped with the Brembo disc brake,
during maintenance, take care not to contact the parts
or tools to the caliper because the paint of caliper will
be scratched. And if there is brake fluid on the caliper,
wipe out quickly.
AB"CASTLE NUT REMOVAL
Caution
Do not apply the vehicle weight to the wheel bearing
while loosening the castle nut. Otherwise wheel bearing
will be damaged.
AC"TIE ROD END DISCONNECTION
Caution
1. Loosen the nut only; do not remove it from the ball
joint. Otherwise ball joint thread will be damaged.
2. The special tool should be suspended by a cord to
prevent it from coming off.
AD"DRIVE SHAFT REMOVAL
1. Use the special tools to push out the drive shaft from
the hub.
2. Withdraw the drive shaft from the hub by pulling the bottom
of the brake disc towards you, and then remove the hub
retaining bolts.
MB990767
Nut
Cord
Ball joint
MB991113 or
MB990635
MB990242 MB990767MB991354
MB990244
(Three)

FRONT AXLE -Drive Shaft26-11
REMOVAL SERVICE POINTS
AA"TIE ROD END DISCONNECTION
Caution
1. Loosen the nut only; do not remove it from the ball
joint. Otherwise ball joint thread will be damaged.
2. The special tool should be suspended by a cord to
prevent it from coming off.
AB"DRIVE SHAFT REMOVAL
1. Use the special tools to push out the drive shaft from
the hub.
2. Withdraw the drive shaft from the hub by pulling the bottom
of the brake disc towards you, and then remove the hub
retaining bolts.
3. Remove the drive shaft from the transmission by the
following procedure.
Insert a pry bar between the transmission case and the
drive shaft, and then pry the drive shaft from the
transmission.
Caution
(1) Do not pull on the drive shaft; doing so will damage
the T.J.; be sure to use the pry bar.
(2) When pulling the drive shaft out from the
transmission, be careful that the spline part of
the drive shaft does not damage the oil seal.
(3) Do not apply the vehicle weight to the wheel
bearing while loosening the drive shaft nut.
Otherwise wheel bearing will be damaged. If,
however, the vehicle weight must be applied to
the bearing (because of moving the vehicle),
temporarily secure the wheel bearing by using
the special tool.
Nut
Cord
Ball joint
MB991113 or
MB990635
MB990242 MB990767MB991354
MB990244
(Three)
T.J. assembly
Pry bar
Transmission
MB991000
(MB990998)
MB991017

POWER PLANT MOUNT - Engine Roll Stopper, Centermember32-7
52±7 N·m*35±5 N·m*
69±10 N·m
49±10 N·m
52±7 N·m*
35±5 N·m*
70±10 N·m
1 2
3 456
1 78
70±10 N·m
69±10 N·m
49±10 N·m

Front roll stopper and centermember
removal steps
1. Crossmember bar
2. Front roll stopper connecting bolt
3. Centermember
"AA4. Front roll stopper
5. Front roll mount bracketRear roll stopper removal steps
6. Rear roll stopper connecting bolt
7. Rear roll mount bracket
8. Rear roll stopper
INSTALLATION SERVICE POINT
"AAFRONT ROLL STOPPER INSTALLATION
Install the front roll stopper so that its hole points towards
the front side of the vehicle.
Hole
Front of vehicle

FRONT SUSPENSION -Special Tools/On-vehicle Service33A-4
Tools UseName Number
MB990800Ball joint remover &
installerLower arm ball joint dust cover press-in
MB990651BarLower arm pillow ball bushing removal and
press-fitting
MB990816Bushing remover &
installer base
MB991576Base
MB990635,
MB991113 or
MB991406Steering linkage
pullerTie rod end and knuckle disconnection
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
Measure the wheel alignment with the vehicle parked on a
level surface.
The front suspension, steering system, and wheels should be
serviced to normal condition prior to measurement of wheel
alignment.
TOE-IN
Standard value:
At the centre of tyre tread 0±2mm
Toe angle (per wheel) 0_00’±05’
1. Adjust the toe-in by undoing the clip and lock nut, and
turning the left and right tie rod turnbuckles by the same
amount (in opposite directions).
NOTE
The toe will move out as the left turnbuckle is turned
toward the front of the vehicle and the right turnbuckle
is turned toward the rear of the vehicle.
2. Install the clip and tighten the lock nut to the specified torque.
Clip
Lock nut

BASIC BRAKE SYSTEM -Brake Pedal/Proportioning Valve,
Master Cylinder and Brake Booster35A-17
INSPECTION
STOP LAMP SWITCH CHECK
1. Connect an ohmmeter between the stop lamp switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
PROPORTIONING VALVE, MASTER CYLINDER AND BRAKE
BOOSTER
REMOVAL AND INSTALLATION
Pre-removal Operation
DAir Intake Hose and Air Cleaner Removal

DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid DrainingPost-installation Operation
DBrake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
DBrake Pedal Adjustment (Refer to P.35A-7.)
DAir Intake Hose and Air Cleaner Installation

DStrut Tower Bar Installation (Refer to GROUP 42.)
510
11 3
12 4
14
15±2N·m 15±2N·m
22±3N·m
10±2N·m
13 2
8
14±3N·m
519

9
15±2N·m
5
Proportioning valves

67
30±5N·m
9
15
16±1N·m

9
15
16±1N·m
Vacuum hose, fitting
Specified Sealant: 3M ATD
Part No.8661, 8663 or
equivalent
15
Fitting
4mm
No continuityContinuity

ABS <4WD> -Hydraulic Unit and ABS-ECU35B-30
HYDRAULIC UNIT AND ABS-ECU
REMOVAL AND INSTALLATION

Pre-removal Operation
DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid DrainingPost-installation Operation
DBrake Fluid Supplying and Brake Line Bleeding
(Refer to GROUP 35A - On-vehicle Service.)
DHydraulic Unit Check (Refer to P.35B-28.)
DStrut Tower Bar Installation (Refer to GROUP 42.)
23
42
2
2
15±2 N·m
25±6 N·m
1
25±6 N·m
Removal steps
AA"1. Harness connector
"AA2. Brake pipe connectionAB"3. Hydraulic unit and ABS-ECU
4. Hydraulic unit bracket assembly

ABS <4WD> -Hydraulic Unit and ABS-ECU35B-31

Pre-removal Operation
DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid Draining
DAir Intake Hose and Air Cleaner RemovalPost-installation Operation
DBrake Fluid Supplying and Brake Line Bleeding
(Refer to GROUP 35A - On-vehicle Service.)
DHydraulic Unit Check (Refer to P.35B-28.)
DAir Intake Hose and Air Cleaner Installation
DStrut Tower Bar Installation (Refer to GROUP 42.)
213
4 2
2
2
15±2 N·m
25±6 N·m
25±6 N·m
Removal steps
AA"1. Harness connector
"AA2. Brake pipe connectionAB"3. Hydraulic unit and ABS-ECU
4. Hydraulic unit bracket assembly

PARKING BRAKES -Parking Brake Drum36-8
REMOVAL SERVICE POINT
AA"REAR BRAKE CALIPER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or similar.
CAUTION: Brembo disc brake
Take care not to contact the parts or tools to the caliper
because the paint of caliper will be scratched. And if
there is brake fluid on the caliper, wipe out quickly.
INSTALLATION SERVICE POINTS
"AAADJUSTER ASSEMBLY INSTALLATION
Install the adjuster assembly so that the shoe adjusting bolt
of left hand wheel is attached towards the rear of the vehicle,
and the shoe adjusting bolt of right hand wheel is towards
the front of the vehicle.
"BASHOE-TO-ANCHOR SPRING INSTALLATION
Install the shoe-to-anchor springs in the order shown in the
illustration.
NOTE
The figure shows the left wheel; for the right wheel, the position
is symmetrical.
INSPECTION
BRAKE LINING AND BRAKE DRUM CHECK
1. Measure the thickness of the brake lining at several places.
Standard value: 2.8 mm
Limit: 1.0 mm
2. If the thickness of the brake lining has worn down to
the limit value or more, replace the shoe and lining
assemblies on both sides of the vehicle.
3. Measure the inside diameter of the brake disc in two
places or more.
Standard value: 168.0 mm
Limit: 169.0 mm
4. If the inside of the brake disc has worn down to the
limit value or more, or if it is excessively worn on one
side, replace the brake disc.
Shoe adjusting
bolt
Rear side
of the ve-
hicle
A14N0009
12
Paint

STEERING -On-vehicle Service37A-7
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
1. With engine running (hydraulic operation), set front wheels
straight ahead.
2. Measure the play on steering wheel circumference before
wheels start to move when slightly moving steering wheel
in both directions.
Limit: 30 mm or less
3. When play exceeds the limit, check for play on steering
shaft connection and steering linkage. Correct or replace.
4. If the free play still exceeds the limit value, set steering
wheel straight ahead with engine stopped. Load 5 N
towards steering wheel circumference and check play.
Standard value: 0 - 10 mm
5. If the play exceeds the standard value, remove steering
gear box and check total pinion torque. (Refer to
P.37A-17.)
STEERING ANGLE CHECK
1. Locate front wheels on turning radius gauge and measure
steering angle.
Standard value:
Inner wheel31_45’±1_30’
Outer wheel27_15’
2. When the angle is not within the standard value, the
toe-in is probably incorrect. Adjust the toe-in.
Standard value: 0±2mm
Adjust the toe-in by undoing the clip and lock nut, and
turning the left and right tie rod turnbuckles by the same
amount (in opposite directions).
3. Recheck the steering angle.
TIE ROD END BALL JOINT TURNING TORQUE
CHECK
1. Disconnect tie rod and knuckle with special tool.
Caution
(1) Loosen the nut of the special tool, but do not
remove it. If it is removed, the ball joint thread
may be damaged.
(2) Tie the special tool with a cord so as not to fall
off.
Clip
Lock nut
Cord
Ball jointNutMB990635,
MB991113 or
MB991406

STEERING - Power Steering Gear Box and Linkage37A-27
2. If the total rotation torque or torque fluctuation does not
meet the standard values, adjust by returning the rack
support cover within a range of 0 to 30_.
Caution
(1) Adjust around the maximum limit of the standard
values.
(2) See that no ratcheting or catching are present
when operating the rack towards the shaft
direction.
(3) Measure the total pinion torque through the whole
stroke of the rack.
3. If the adjustment is impossible in the given range, check
the components of the rack support cover, and replace
if necessary.
"LATAB WASHER/TIE ROD INSTALLATION
After installing the tie rod to the rack, fold the tab washer
end (2 locations) to the tie rod notch.
"MABELLOWS BAND INSTALLATION
1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
Standard value (W): 2.9 mm

Screw in the adjusting bolt.

Loosen the adjusting bolt.
NOTE
(1) The dimension (W) is adjusted by about 0.7 mm per
one turn.
(2) Do not turn the adjusting bolt more than one turn.
2. Use the special tool to crimp the bellows band.
Caution
(1) Hold the rack housing, and use the special tool
to crimp the bellows band securely.
(2) Crimp the bellows band until the special tool
touches the stopper.
MB991561
Stopper
Adjusting bolt W
MB991561